Yamaha WaveRunner GP800R Manuals

Manuals and User Guides for Yamaha WaveRunner GP800R. We have 2 Yamaha WaveRunner GP800R manuals available for free PDF download: Service Manual, Assembly Manual

Yamaha WaveRunner GP800R Service Manual

Yamaha WaveRunner GP800R Service Manual (247 pages)

Brand: Yamaha | Category: Boat | Size: 12.43 MB

Table of Contents

Info Chapter 1 General Information

9
- How to Use this Manual
  3
- Table of Contents
  9
- Chapter 1
  10
- Engine Serial Number
  10
- HULL IDENTIFICATION NUMBER (H.l.n.)
  10
- Identification Numbers
  10
- Jet Pump Unit Serial Number
  10
- PRIMARY L.D. NUMBER
  10
- Fire Prevention
  11
- Oils, Greases and Sealing Fluids
  11
- Safety While Working
  11
- Self-Protection
  11
- Ventilation
  11
- Good Working Practices
  12
- Disassembly and Assembly
  13
- Special Tools
  14
  - Measuring
    14
  - Removal and Installation
    15
Specifications

17
- Chapter 2 Specifications
  18
- General Specifications
  18
- Maintenance Specifications
  20
  - Engine
    20
  - Jet Pump Unit
    21
  - Hull and Hood
    21
  - Electrical
    22
- Tightening Torques
  24
  - Specified Torques
    24
  - General Torque
    27
- Cable and Hose Routing
  28
Table of Contents

31
- Chapter 3
  32
- Maintenance Interval Chart
  32
- Periodic Service
  33
  - Control System
    33
    
    Steering Column Inspection
    33
    
    Steering Cable Inspection and Adjustment
    33
    
    Throttle Cable Inspection and Adjustment
    34
    
    Choke Cable Inspection and Adjustment
    35
    
    QSTS Cable Inspection and Adjustment
    36
    
    YPVS Cable Adjustment
    37
  - Fuel System
    38
    
    Fuel Line Inspection
    38
    
    Trolling Speed Check and Adjustment
    39
  - Oil Injection System
    40
    
    Oil Line Inspection
    40
  - Power Unit
    40
    
    Spark Plug Inspection
    40
  - Electrical
    41
    
    Battery Inspection
    41
  - Jet Pump Unit
    44
    
    Impeller Inspection
    44
    
    Water Inlet Strainer Inspection
    45
    
    Bilge Strainer Inspection
    45
  - General
    45
    
    Drain Plug Inspection
    45
    
    Lubrication Points
    46
Table of Contents

50
- Chapter 4 Service Points
  53
- Fuel Cock Inspection
  53
- Oil Tank
  54
  - Exploded Diagram
    54
  - Removal and Installation Chart
    54
  - Service Points
    56
    
    Oil Line Inspection
    56
    
    Oil Level Sensor Inspection
    56
    
    Oil Tank Inspection
    56
- Fuel Tank
  57
  - Exploded Diagram
    57
  - Removal and Installation Chart
    57
  - Service Points
    60
    
    Check Valve Inspection
    60
    
    Fuel Level Sensor Inspection
    60
    
    Fuel Tank Inspection
    60
    
    Pipe Joint Inspection
    60
- Intake Silencer
  61
  - Exploded Diagram
    62
  - Removal and Installation Chart
    62
- Carburetor Unit
  62
- Carburetor
  71
  - Removal and Installation Chart
    71
  - Service Points
    74
    
    Diaphragm Inspection
    74
    
    Accelerator Pump Body Inspection
    74
    
    Arm Inspection
    74
    
    Regulator Body Inspection
    75
    
    Needle Valve Inspection
    75
    
    Jet and Carburetor Body Inspection
    75
    
    Carburetor Assembly
    75
- Fuel Pump
  76
  - Exploded Diagram
    76
  - Removal and Installation Chart
    76
  - Service Points
    78
    
    Fuel Pump Inspection
    78
    
    Fuel Filter Inspection
    78
- Oil Pump
  79
  - Exploded Diagram
    79
  - Removal and Installation Chart
    79
  - Service Points
    81
    
    Oil Pump Inspection
    81
    
    Oil Hose Inspection
    81
    
    Check Valve Inspection
    81
    
    Oil Pump Cable Adjustment
    81
    
    Oil Injection Pump Air Bleeding
    82
Powr Chapter 5 Power Unit

84
- Chapter 5
  86
- Engine Unit
  86
- Exploded Diagram
  86
- Removal and Installation Chart
  86
- Service Points
  90
  - Shim Removal
    90
  - Engine Mount Inspection
    90
  - Coupling Clearance Inspection
    90
- Exhaust Chamber Assembly
  91
  - Exploded Diagram
    91
  - Removal and Installation Chart
    91
- Exhaust Chamber Joint
  95
  - Exploded Diagram
    95
  - Removal and Installation Chart
    95
- Exhaust Manifold
  97
  - Exploded Diagram
    97
  - Removal and Installation Chart
    97
- Reed Valves
  98
  - Exploded Diagram
    98
  - Removal and Installation Chart
    98
  - Service Points
    99
    
    Reed Valve Inspection
    99
- Ypvs
  100
  - Exploded Diagram
    100
  - Service Points
    102
    
    YPVS Valve Inspection
    102
    
    YPVS Valve Installation
    102
- Cylinder Head
  103
  - Exploded Diagram
    103
  - Removal and Installation Chart
    103
  - Service Points
    104
    
    Cylinder Head Inspection
    104
- Cylinders
  105
  - Exploded Diagram
    105
  - Removal and Installation Chart
    105
  - Service Points
    106
    
    Cylinder Inspection
    106
- Pistons
  107
  - Exploded Diagram
    107
  - Removal and Installation Chart
    107
  - Service Points
    109
    
    Piston Pin Clip Removal and Installation
    109
    
    Piston Inspection
    109
    
    Cylinder and Piston Combination
    110
    
    Piston Ring Inspection
    110
    
    Piston Pin and Bearing Inspection
    111
- Starter Motor
  113
  - Exploded Diagram
    115
- Flywheel Magneto
  115
  - Exploded Diagram
    116
  - Service Points
    119
    
    Drive Coupling Removal and Installation
    119
    
    Flywheel Magneto Removal and Installation
    119
    
    Drive Coupling Inspection
    120
    
    Flywheel Magneto Inspection
    120
    
    Starter Clutch Assembly Inspection
    120
- Crankcase
  121
  - Exploded Diagram
    121
  - Service Points
    123
    
    Crankcase Inspection
    123
    
    Crankcase Installation
    123
- Crankshaft
  124
  - Exploded Diagram
    124
  - Service Points
    125
    
    Crankshaft Inspection
    125
Pump Chapter 6 Jet Pump Unit

127
- Chapter 6 Jet Pump Unit
  128
- Exploded Diagram
  130
- Nozzle Deflector and Nozzle Ring
  131
  - Exploded Diagram
    131
- Impeller Duct, Impeller Housing, and Intake Duct
  132
  - Exploded Diagram
    132
  - Removal and Installation Chart
    132
- Impeller Duct and Drive Shaft
  134
  - Exploded Diagram
    134
  - Service Points
    136
    
    Drive Shaft Removal
    136
    
    Impeller Inspection
    137
    
    Drive Shaft Inspection
    137
    
    Drive Shaft Installation
    137
- Transom Plate and Hoses
  140
  - Exploded Diagram
    140
  - Removal and Installation Chart
    140
  - Service Points
    142
    
    Bilge Strainer Inspection
    142
    
    Bilge Hose Inspection
    142
- Bearing Housing
  143
  - Exploded Diagram
    143
  - Removal and Installation Chart
    143
  - Service Points
    146
    
    Driven Coupling Removal and Installation
    146
    
    Intermediate Drive Shaft Removal
    146
    
    Bearing Removal
    146
    
    Bearing, Driven Coupling Shaft, and Grease Hose Inspection
    147
    
    Driven Coupling Inspection
    147
    
    Bearing Installation
    147
    
    Oil Seal Installation
    147
    
    Intermediate Housing Installation
    148
Table of Contents

150
- Chapter 7
  152
- Electrical Components
  152
- Electrical Box
  153
  - Exploded Diagram
    153
- Electrical Analysis
  157
  - Inspection
    157
    
    Digital Tester
    157
    
    Low Resistance Measurement
    157
    
    Peak Voltage Measurement
    158
    
    Peak Voltage Adaptor
    158
    
    Test Harness
    159
- Ignition System
  160
  - Wiring Diagram
    160
  - Ignition Spark Gap
    161
  - Ignition System Peak Voltage
    162
  - Spark Plugs
    163
  - Spark Plug Caps
    163
  - Ignition Coil
    163
  - Engine Stop Switch
    164
  - Thermoswitch
    164
- Starting System
  165
  - Wiring Diagram
    165
  - Battery
    166
  - Wiring Connections
    166
  - Fuse
    166
  - Starter Switch
    166
  - Starter Relay
    167
- Starter Motor
  168
  - Exploded Diagram
    168
  - Service Points
    171
    
    Armature Inspection
    171
    
    Brush Holder Inspection
    172
    
    Starter Motor Front Cover Inspection
    172
- Charging System
  173
  - Wiring Diagram
    173
  - Fuse
    174
  - Battery
    174
  - Rectifier/Regulator Peak Voltage
    174
  - Lighting Coil Peak Voltage
    174
- Ypvs
  175
  - Wiring Diagram
    175
  - Fuse
    176
  - Battery
    176
  - Pickup Coil
    176
  - CDI Unit
    176
- Ypvs Servomotor
  178
  - Service Points
    178
    
    YPVS Cable Removal and Installation
    178
    
    YPVS Cable Inspection
    178
    
    YPVS Servomotor Inspection
    178
    
    YPVS Cable Adjustment
    179
- Indication System
  180
  - Wiring Diagram
    180
  - Fuse
    181
  - Battery
    181
  - Lighting Coil
    181
  - Rectifier/Regulator
    181
  - CDI Unit
    181
  - Thermoswitch
    181
  - Buzzer
    181
  - Oil Level Sensor
    181
  - Fuel Level Sensor
    182
  - Multifunction Meter
    182
  - Multifunction Meter Removal
    182
    
    Display Function
    183
    
    Fuel Level Gauge
    184
    
    Oil Level Gauge
    185
    
    Overheat Warning Indicator
    186
    
    Speed Meter
    187
    
    Speed Sensor
    188
Hull and Hood

190
- Chapter 8
  194
- Handlebar
  194
- Removal and Installation Chart
  194
- Service Points
  198
  - Handlebar Inspection
    198
  - Handlebar Switch Inspection
    198
  - Handlebar Assembly Installation
    198
- Service Points
  203
  - QSTS Cable Inspection
    203
  - QSTS Grip Inspection
    203
- Steering Column
  204
  - Exploded Diagram
    204
  - Removal and Installation Chart
    204
  - Service Points
    207
    
    Steering Column Bushing Inspection
    207
- Remote Control Cables and Speed Sensor Lead
  209
  - Exploded Diagram
    209
  - Removal and Installation Chart
    210
  - Service Points
    211
    
    Remote Control Cables Inspection
    211
    
    Steering Cable (Jet Pump Side) Installation
    211
    
    Steering Cable Stopper Installation
    211
    
    QSTS Cable (Jet Pump Side) Installation
    212
    
    QSTS Cable Stopper Installation
    212
- Front Hood
  213
  - Exploded Diagram
    213
  - Removal and Installation Chart
    213
- Hull Hood
  215
  - Exploded Diagram
    216
  - Removal and Installation Chart
    217
- Steering Console Cover
  215
  - Exploded Diagram
    215
  - Removal and Installation Chart
    215
- Hoses
  222
  - Exploded Diagram
    222
  - Removal and Installation Chart
    222
  - Service Points
    224
    
    Check Valve Inspection
    224
    
    Ventilation Hose Installation
    224
  - Service Points
    227
    
    Seat Lock Inspection
    227
- Battery Box
  228
  - Exploded Diagram
    228
  - Removal and Installation Chart
    228
- Exhaust System
  230
  - Exploded Diagram
    230
  - Removal and Installation Chart
    230
  - Service Points
    232
    
    Exhaust System Inspection
    232
    
    Exhaust Component Parts Sub-Assembly
    232
- Deck and Hull
  233
  - Exploded Diagram
    233
  - Removal and Installation Chart
    233
- Engine Mount
  235
  - Exploded Diagram
    235
  - Removal and Installation Chart
    235
  - Hull Repair
    236
    
    Shallow Scratches
    236
    
    Deep Scratches
    236
    
    Cracks and Punctures
    237
    
    Insert Nut
    238
    
    Graphic Removal
    240
    
    Graphic Installation
    240

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Yamaha WaveRunner GP800R Assembly Manual

Yamaha WaveRunner GP800R Assembly Manual (25 pages)

Brand: Yamaha | Category: Boat | Size: 1.33 MB

Table of Contents

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